ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
AT-41
[EURO-OBD]
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Malfunction Indicator lamp (MIL)ECS004QL
1. The malfunction indicator lamp will light up when the ignition
switch is turned ON without the engine running. This is for
checking the lamp.
●If the malfunction indicator does not light up, refer to DI-43,
"Schematic" .
(Or see MIL & CONSULT-II in EC section. Refer to EC-58,
"Malfunction Indicator (MI)" (QR25DE) or EC-790, "Malfunc-
tion Indicator (MI)" (QR20DE), EC-94, "CONSULT-II Func-
tion" (QR25DE) or EC-826, "CONSULT-II Function"
(QR20DE).
2. When the engine is started, the malfunction indicator should go
off.
If the lamp remains on, the on board diagnostic system has detected an emission-related (EURO-OBD)
malfunction. For detail, refer to EC-44, "
ON BOARD DIAGNOSTIC (OBD) SYSTEM" (QR25DE) or EC-
777, "ON BOARD DIAGNOSTIC (OBD) SYSTEM" (QR20DE).
CONSULT-IIECS004QM
After performing “SELF-DIAGNOSTIC PROCEDURE (WITH CONSULT-II)” AT- 4 1 , place check marks for
results on the “DIAGNOSTIC WORKSHEET”, AT- 5 7
. Reference pages are provided following the items.
NOTICE:
1. The CONSULT-II electrically displays shift timing and lock-up timing (that is, operation timing of each sole-
noid).
Check for time difference between actual shift timing and the CONSULT-II display. If the difference is
noticeable, mechanical parts (except solenoids, sensors, etc.) may be malfunctioning. Check mechanical
parts using applicable diagnostic procedures.
2. Shift schedule (which implies gear position) displayed on CONSULT-II and that indicated in Service Man-
ual may differ slightly. This occurs because of the following reasons:
–Actual shift schedule has more or less tolerance or allowance,
–Shift schedule indicated in Service Manual refers to the point where shifts start, and
–Gear position displayed on CONSULT-II indicates the point where shifts are completed.
3. Shift solenoid valve “A” or “B” is displayed on CONSULT-II at the start of shifting. Gear position is dis-
played upon completion of shifting (which is computed by TCM).
4. Additional CONSULT-II information can be found in the Operation Manual supplied with the CONSULT-II
unit.
SELF-DIAGNOSTIC PROCEDURE (WITH CONSULT-II)
1. Turn on CONSULT-II and touch “ENGINE” for EURO-OBD
detected items or touch “A/T” for TCM self-diagnosis.
If A/T is not displayed, check TCM power supply and ground cir-
cuit. Refer to AT- 1 0 6 , "
TCM Terminals and Reference Value" . If
result is NG, refer to PG-2, "
POWER SUPPLY ROUTING" .
SAT652J
SAT014K
TROUBLE DIAGNOSIS — INTRODUCTION
AT-57
[EURO-OBD]
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DIAGNOSTIC WORKSHEET
Information from Customer
KEY POINTS
●WHAT..... Vehicle & A/T model
●WHEN..... Date, Frequencies
●WHERE..... Road conditions
●HOW..... Operating conditions, Symptoms
Customer name MR/MS Model & Year VIN
Trans. model Engine Mileage
Incident Date Manuf. Date In Service Date
Frequency❏ Continuous❏ Intermittent ( times a day)
Symptoms❏ Vehicle does not move. (❏ Any position❏ Particular position)
❏ No up-shift (❏ 1st → 2nd❏ 2nd → 3rd❏ 3rd → O/D)
❏ No down-shift (❏ O/D → 3rd❏ 3rd → 2nd❏ 2nd → 1st)
❏ Lockup malfunction
❏ Shift point too high or too low.
❏ Shift shock or slip (❏ N → D❏ Lockup❏ Any drive position)
❏ Noise or vibration
❏ No kick down
❏ No pattern select
❏ Others
()
O/D OFF indicator lamp Blinks for about 8 seconds.
❏ Continuously lit❏ Not lit
Malfunction indicator lamp (MIL)❏ Continuously lit❏ Not lit
AT-62
[EURO-OBD]
TROUBLE DIAGNOSIS — INTRODUCTION
*1:AT-57, "Information from Customer"*2:AT-58, "Diagnostic Worksheet"*3:AT- 7 , "Service Notice or Pre-
cautions"
*4:AT-63, "A/T Fluid Check"*5:AT-64, "Sta ll Tes t" and AT-67, "Line Pressure
Te s t"
*6:AT-68, "Road Test"
*7:AT-41, "CONSULT-II"*8:AT-37, "ON BOARD DIAGNOSTIC SYSTEM
DESCRIPTION"
*9:AT-50, "Diagnostic Procedure
Without CONSULT-II"
*10:AT- 11 0 , "DTC P0705 PARK/NEU-
TRAL POSITION (PNP) SWITCH"
*11:AT-199, "DTC VEHICLE SPEED SENSOR
MTR" and AT-203, "DTC CONTROL UNIT
(RAM), CONTROL UNIT (ROM)" t o AT-205,
"DTC CONTROL UNIT(EEPROM)"
*12:AT-209, "O/D OFF Indicator
Lamp Does Not Come On"
*13:AT-240, "Vehicle Does Not Deceler-
ate By Engine Brake"
*14:AT-86, "Symptom Chart"*15:AT-39, "HOW TO ERASE DTC"
*16:AT- 111 , "DIAGNOSTIC TROUBLE
CODE (DTC) CONFIRMATION
PROCEDURE"
*17:AT-199, "DTC VEHICLE SPEED SENSOR
MTR" and AT-203, "DTC CONTROL UNIT
(RAM), CONTROL UNIT (ROM)" t o AT-205,
"DTC CONTROL UNIT(EEPROM)"
*18: EC section
TROUBLE DIAGNOSIS — INTRODUCTION
AT-259
[EXC.F/EURO-OBD]
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DIAGNOSTIC WORKSHEET
Information from Customer
KEY POINTS
●WHAT..... Vehicle & A/T model
●WHEN..... Date, Frequencies
●WHERE..... Road conditions
●HOW..... Operating conditions, Symptoms
Customer name MR/MS Model & Year VIN
Trans. model Engine Mileage
Incident Date Manuf. Date In Service Date
Frequency❏ Continuous❏ Intermittent ( times a day)
Symptoms❏ Vehicle does not move. (❏ Any position❏ Particular position)
❏ No up-shift (❏ 1st → 2nd❏ 2nd → 3rd❏ 3rd → O/D)
❏ No down-shift (❏ O/D → 3rd❏ 3rd → 2nd❏ 2nd → 1st)
❏ Lockup malfunction
❏ Shift point too high or too low.
❏ Shift shock or slip (❏ N → D❏ Lockup❏ Any drive position)
❏ Noise or vibration
❏ No kick down
❏ No pattern select
❏ Others
()
O/D OFF indicator lamp Blinks for about 8 seconds.
❏ Continuously lit❏ Not lit
AT-496
[ALL]
REPAIR FOR COMPONENT PARTS
ASSEMBLY
1. Attach side gear thrust washers to side gears, then install pinion
mate thrust washers and pinion mate gears in place.
2. Insert pinion mate shaft.
●When inserting, be careful not to damage pinion mate
thrust washers.
3. Measure clearance between side gear and differential case with
washers following the procedure below:
a. Set Tool and dial indicator on side gear.
b. Move side gear up and down to measure dial indicator deflec-
tion. Always measure indicator deflection on both side gears.
c. If not within specification, adjust clearance by changing thickness of differential side gear thrust washers.
SMT839
SMT087A
SMT097CA
Clearance between side gear and differential case
with washer:
0.1 - 0.2 mm (0.004 - 0.008 in)
SMT611A
Differential side gear thrust washers:
Refer to AT-521, "
SERVICE DATA AND SPECIFICA-
TIONS (SDS)" .
ASSEMBLY
AT-499
[ALL]
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Adjustment (1)ECS004ME
DIFFERENTIAL SIDE BEARING PRELOAD
1. Install differential side bearing outer race without adjusting shim
on transmission case.
2. Install differential side bearing outer race on converter housing.
3. Place final drive assembly on transmission case.
4. Install transmission case on converter housing. Tighten trans-
mission case fixing bolts to the specified torque. Refer to AT-
421, "OVERHAUL" .
5. Attach dial indicator on differential case at converter housing
side.
6. Insert Tool into differential side gear from transmission case
side.
7. Move Tool up and down and measure dial indicator deflection.
8. Select proper thickness of differential side bearing adjusting
shim(s).
Suitable shim thickness = Dial indicator deflection + Speci-
fied bearing preload
SAT870D
SAT008F
Differential side bearing preload adjusting shim:
Refer to AT- 5 2 1 , "
SERVICE DATA AND SPECIFICA-
TIONS (SDS)" .
Bearing preload:
0.05 - 0.09 mm (0.0020 - 0.0035 in)
SAT186FA
TF-1
TRANSFER
D DRIVELINE/AXLE
CONTENTS
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SECTION
A
B
TF
TRANSFER
PRECAUTIONS .......................................................... 3
Caution ..................................................................... 3
PREPARATION ........................................................... 4
Special Service Tools ............................................... 4
NOISE, VIBRATION, AND HARSHNESS (NVH)
TROUBLESHOOTING ................................................ 7
NVH Troubleshooting Chart ..................................... 7
TRANSFER FLUID ..................................................... 8
Replacement ............................................................ 8
DRAINING ............................................................. 8
FILLING ................................................................. 8
Inspection ................................................................. 8
OIL LEAKAGE AND OIL LEVEL ........................... 8
SIDE OIL SEAL .......................................................... 9
Removal and Installation .......................................... 9
REMOVAL ............................................................. 9
INSTALLATION ..................................................... 9
AIR BREATHER HOSE ............................................ 10
Removal and Installation ........................................ 10
TRANSFER ASSEMBLY ...........................................11
Removal and Installation from Vehicle .................... 11
REMOVAL ............................................................ 11
INSTALLATION .................................................... 11
Component Parts Drawing ..................................... 13
Assembly Inspection .............................................. 14
BACKLASH ......................................................... 14
TOOTH CONTACT .............................................. 14
PRELOAD TORQUE ........................................... 16
COMPANION FLANGE RUNOUT ...................... 17
Disassembly and Assembly ................................... 18
DISASSEMBLY ................................................... 18
INSPECTION AFTER DISASSEMBLY ............... 22
SELECTIONG ADJUSTING SHIMS ................... 23
ASSEMBLY ......................................................... 24
ALL MODE 4X4 SYSTEM ........................................ 30
Precautions ............................................................ 30
System Component ................................................ 30
System Description ................................................ 30
ELECTRONIC COUPLING ................................. 30
4WD CONTROL UNIT ........................................ 304WD MODE SWITCH ......................................... 31
4WD WARNING LAMP ....................................... 31
FAIL- SAFE FUNCTION ...................................... 32
System Diagram ..................................................... 32
CAN Communication ...........................................
... 32
SYSTEM DESCRIPTION .................................... 32
SYSTEM DIAGRAM ............................................ 32
INPUT/OUTPUT SIGNAL .................................... 33
Circuit Diagram ....................................................... 34
Wiring Diagram ....................................................... 35
TROUBLE DIAGNOSIS ............................................ 40
Fail-safe function .................................................... 40
How to proceed with trouble diagnosis ................... 40
BASIC CONCEPT ............................................... 40
Trouble diagnosis chart by symptom ...................... 41
4WD control unit input/output signal standard ........ 42
4WD CONTROL UNIT CONNECTOR TERMI-
NAL ARRANGEMENT ........................................ 42
REFERENCE STANDARD TABLE ...................... 43
CONSULT-II functions ............................................ 45
CONSULT-II FUNCTION APPLICATION TABLE ... 45
SELF-DIAGNOSIS .............................................. 45
DATA MONITOR ................................................. 46
ACTIVE TEST ..................................................... 48
ECU PART NUMBER .......................................... 49
Component Inspection ............................................ 49
4WD SOLENOID VALVE ..................................... 49
System Inspection .................................................. 49
CONTROL UNIT POWER SUPPLY SYSTEM .... 49
G-SENSOR SYSTEM ......................................... 50
4WD SOLENOID, ACTUATOR RELAY SYSTEM ... 52
CAN COMMUNICATION SYSTEM ..................... 53
4WD MODE SWITCH SYSTEM .......................... 54
Trouble Diagnoses for Symptoms .......................... 55
4WD INDICATOR LAMP DOSE NOT COME ON
FOR APPROXIMATELY 1 SECOND WHEN THE
IGNITION SWITCH IS TURNED TO ON ............. 55
4WD WARNING LAMP DOES NOT ILLUMINATE
WITH IGNITION ON ............................................ 55
4WD WARNING LAMP DOES NOT GO OUT
TF-2
SEVERAL SECONDS AFTER ENGINE
STARTED.(4WD MODE INDICATOR LAMP
GOES OUT) ........................................................ 56
HEAVY TIGHT-CORNER BRAKING SYMPTOM
OCCURS WHEN THE VEHICLE IS DRIVEN IN
AUTO MODE AND THE STEERING WHEEL IS
TURNED FULLY TO EITHER SIDE AFTER THE
ENGINE IS STARTED ......................................... 56
4WD MODES CANNOT BE SWITCHED AFTER
ENGINE IS STARTED ......................................... 57
WHILE DRIVING, 4WD WARNING LAMP
FLASHES RAPIDLY. (WHEN IT FLASHERS FOR
APPROX. ONE MINUTE, THEN DOES NOT
ILLUMINATE.) ..................................................... 57
WHILE DRIVING, 4WD WARNING LAMP
FLASHES SLOWLY. (WHEN IT CONTINUES TO
ILLUMINATE UNTIL ENGINE TURNS OFF.) ...... 57
VEHICLE DOES NOT ENTER 4WD MODE EVEN THOUGH 4WD WARNING LAMP IS OFF. ... 58
TIGHT-CONER BRAKING SYMPTOM OCCURS
WHEN THE VEHICLE IS STARTED IN AUTO
WARNING LAMP REMAIN OFF). ....................... 58
4WD ACTUATOR RELAY (4WD SOLENOID
ACTUATOR RELAY) TURNS ON/OFF FRE-
QUENTLY ............................................................ 58
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 59
General Specifications ......................................... ... 59
Inspection and Adjustment ...................................... 59
PRELOAD TORQUE BEFORE DISASSEMBLY ... 59
PRELOAD TORQUE AFTER DISASSEMBLY
AND REASSEMBLY ............................................ 59
BACKLSH ............................................................ 59
COMPANION FLANGE RUNOUT ....................... 59
SELECTIVE PARTS ............................................ 59
PINION SLEEVE SHIM ........................................ 60